Highly stabilized colloidal system and its industrial applications

ABSTRACT

The present investigation related to a new colloidal system which can improve the physical, mechanical and chemical properties of basic and/or neutral products, in particular, premixed building materials based on silicon, calcium carbonate, plaster, containing hydraulic and aerial binders; refractory materials based on alumina, magnesite, chromite, zirconium, etc.; varnishes stuccos, plasters, plastic materials polymers, and similar. Among the improvements of the physical, mechanical and chemical properties of materials, there are thermal isolation, UV-rays resistance, corrosion resistance and mechanical resistance, elasticity, scratch resistance, fixing to the supporting base, the reduction of thermal expansion.

TECHNICAL FIELD

The present investigation related to a new colloidal system which can improve the physical, mechanical and chemical properties of basic and/or neutral products, in particular, premixed building materials based on silicon, calcium carbonate, plaster, containing hydraulic and aerial binders; refractory materials based on alumina, magnesite, chromite, zirconium, etc.; varnishes stuccos, plasters, plastic materials polymers, and similar.

Among the improvements of the physical, mechanical and chemical properties of materials, there are thermal isolation, UV-rays resistance, corrosion resistance and mechanical resistance, elasticity, scratch resistance, fixing to the supporting base, the reduction of thermal expansion.

DISCLOSURE OF THE INVENTION

These advantages can be realized by this innovative colloidal system highly stabilized which, mixed with inerts, various binders, plastic materials, natural and synthetic rubber, liquid polymers, improves the physical, mechanical and chemical properties of materials. This system is characterized by a liquid phase (from 30 to 45% in volume) comprising saturated hydrocarbons C15-C20, unsaturated hydrocarbons C18-C25, paraffinic mineral oil, and by a solid phase (from 55 to 70% in volume) comprising a Carbon fraction, a thickener/coagulator, Calcium carbonate alumina and other salts.

These and other advantages will be shown in the detailed description of the invention which provides some practical examples, descriptive but not restrictive of the application of the new composition.

WAY OF CARRYING OUT THE INVENTION

The new composition invented comprises a liquid phase and a solid phase. The liquid phase, whose percentage in volume ranges between 30 and 45%, comprises a fraction of saturated hydrocarbons (C15-C20) between 60% and 80%, (molecular structures with very high activation energy) which diffused in paraffinic oils give chemical stability and density and viscosity to the product; a fraction of unsaturated hydrocarbons (C18-C25) between 10% and 30%, which are more reactive and promote oxidation; their reactivity is useful to dry thin layers; a fraction of mineral oil (both paraffinic and siliconic oil) in a percentage of 10% and 30% which make the mixture apt to a plastic application. The solid phase whose percentage in volume ranges between 55 and 70%, comprises a carbon fraction between 60% and 85%, deriving from hydrocarbons combustion residuals, a thickener from 8% to 20%, which works as a homogenizator, to confer a sort of superficial polimerization to the product. Optionally, there can be also metal oxides salts which amalgamated/blended to the emulsion up to 10%.

Thanks to its chemical and physical properties this innovative system can be applied as a binder or a release agent in the working of plastic materials. The chemical-physical process differs according to the type of basic material to which it is added. In all cases, however, it starts homogenization and cohesion processes which turn the structure into microstructures with microporosity. It is a process of maturation in the case of concrete of any type (refractory and concrete or civil use) plasters, limes, chalk; it is a polymerization process in the case of varnishes, resins, bitumen, rubber, etc.; it is a ceramization process in the case of bricks and ceramic products in general.

The new system can be used as it is (creamy), that is, added with the mentioned products in a percentage ranging between 0.01% and 3-4%; or it can be used as liquid or powder, that is added with other products (for examples based on silicon, alumina, magnesite, calcium oxide or zirconium) in a percentage ranging between 1% and 20%. The additive is used in indirect form, that is mixed with other compounds, and is added with other products in a percentage ranging between up to 20%.

The advantages coming from the use of the innovation comprise a remarkable improvement of the physical, mechanical and chemical properties of materials, like thermal isolation, and mechanical resistance, fixing properties, higher elasticity, lower expansions; and other physical properties like waterproofing, UV-rays resistance, corrosion resistance, keeping the colors.

Laboratory tests were carried out to prove what it has been said. In particular:

-   -   UV-rays resistance test: the calcareous and siliceous specimen         smeared with the emulsion invented, were subject to UV-rays for         720 hours, without degrading the surface. On the contrary the         surface appears vetrified.     -   Mechanical resistance test: the same specimens showed an         increase of the breaking load higher than 15% after 12 hours.         Furthermore, SEM observation of the surfaces has shown the         inclusion of intercrystal cracks (picture n. 2) and the loss of         continuity of the structure compared to the non-additivated         specimen;     -   Corrosion resistance test: the sample kept in salt mist and         saturated humidity atmosphere did not suffer from structural         change.

As an example the results of the tests carried out in accredited laboratories. In particular, the output of pictures 3 and 4 refer to an elastomeric sheath treated with the present colloidal system after 1000 hour exposure to salt mist. The colloidal system added to a standard dry premixed cement plaster, produced a remarkable improvement of the penetration resistance, to flexion and compression resistance, cloride ion and sulfate ion penetrability, water absorption by capillarity, as reported in table 1.

The colloidal system added to a standard cement produces a fluidifying effect which is higher than a non-added cement, but lower that a cement added with a commercial superfluidifier. The compression resistance test shows that the cement mixed with the invented colloidal system presents low values at the beginning and high values after. In other words, the cement maturation with the colloidal system is lower (which allows longer times of workability) but the values reached in time are higher than those of other compositions.

The additivated cement gives a higher resistance to cloride ion and sulfate ion penetration and, keeping the cement PH constant, increases its durability.

Picture 5 and 6 show the homogenization and cohesion process which transforms the refractory cement into a microstructure with microporosity Non-additivated cement, in fact, has a more irregular surface (pict.n.5) compared with the additivated sample which appears much more compact (picture n. 6).

EXAMPLE

According to some examples the qualitative and quantitative analysis are reported:

Sample 2a: comprises a liquid phase (45%) and a solid phase (55%) well emulsionated. The liquid phase comprises saturated hydrocarbons C15-C20 (50%), unsaturated hydrocarbons C18-C25 (50%), paraffinic mineral oil (20%). The solid phase comprises a carbon fraction (83%) a thickener (8%) and calcium carbonate (9&).

Sample 3a: comprises a liquid phase (35.5%) and a solid phase (64.5%) well emulsionated. The liquid phase comprises saturated hydrocarbons C15-C20 (40%), unsaturated hydrocarbons C18-C25 (30%), paraffinic mineral oil (30%). The solid phase comprises a carbon fraction (78-5%) a thickener (12.5%) and 10 calcium carbonate (9%).

Sample 4a: comprises a liquid phase (21.5%) and a solid phase (78.5%) well emulsionated. The liquid phase comprises saturated hydrocarbons C15-C20 (65%), unsaturated hydrocarbons C18-C25 (25%), paraffinic mineral oil (10%). The solid phase 15 comprises a carbon fraction (73%) a thickener (7%) and calcium carbonate (13%) and alumina (7%).

Sample 6a: comprises a liquid phase (15.5%) and a solid phase (84.5%) well emulsionated. The liquid phase comprises saturated hydrocarbons C15-C20 (75%), unsaturated hydrocarbons C18-C25 (10%), paraffinic mineral oil (15%). The solid phase comprises a carbon fraction (70%) a thickener (10%) and calcium carbonate (10%) and alumina (10%). 

1) Highly stabilized innovative colloidal system which, mixed with inerts, various binders, plastic materials, natural and synthetic rubber, and liquid polymers, improves the physical, mechanical and chemical properties of materials. This system is characterized by a liquid phase (from 30 to 45% in volume) comprising saturated hydrocarbons C15-C20, unsaturated hydrocarbons C18-C25, paraffinic mineral oil, and by a solid phase (from 55 to 70% in volume) comprising a Carbon fraction, a thickener, Calcium carbonate, alumina and other salts. 2) Highly stabilized innovative colloidal system according to claim 1, characterized by the fact that those hydrocarbons comprise saturated hydrocarbons (C15-C20) between 60% and 80% of said liquid phase, and unsaturated hydrocarbons (C18-C25) between 10% and 30%. 3) Highly stabilized innovative colloidal system according to claims 1 and 2, characterized by the fact that said mineral oil (both paraffinic and siliconic oil) has a percentage of 60% to 85% of the solid phase. 4) Highly stabilized innovative colloidal system according to claim 1, characterized by the fact that said carbon fraction has a percentage of 10% to 30% of the liquid phase. 5) Highly stabilized innovative colloidal system according to claim 1, characterized by the fact that said thickener has a percentage of 8% to 20% of the solid phase. 6) Highly stabilized innovative colloidal system according to claim 1, characterized by the fact that it can be used both liquid and creamy. 7) Highly stabilized innovative colloidal system according to claims 6, characterized by the fact that it can be used as it is, that is, added to those compounds mentioned in claim 1 in percentage ranging from 0.01% and 3-4%. 8) Highly stabilized innovative colloidal system according to claim 1, characterized by the fact that it can mixed to other products (for example, based on alumina, magnesite, calcium oxide or zirconium) in wider percentage from 1% to 20%. 9) Highly stabilized innovative colloidal system according to claim 8, characterized by the fact that it can be used as it is (as a powder or liquid) and is added to other compounds up to 20% 10) Highly stabilized innovative colloidal system according to claim 1, characterized by the fact that it implies chemical-physical process, a homozaneization and cohesion process, which transforms the structure of the material into a microstructure with microporosity. 11) Highly stabilized innovative colloidal system according to claim 1, characterized by the fact that it can be added to any type of concrete (refractary and concrete for civil.,e) plasters, limes, chalk, varnishes, resins, bitumen, rubber, bricks and ceramic products in general. 12) Highly stabilized innovative colloidal system according to claim 11, characterized by the fact that it can give the products mentioned in claim 11 a high thermal isolation, higher UV-rays resistance, increased corrosion resistance and mechanical resistance, higher elasticity, increased scratch resistance, better fixing to the supporting base and a increased reduction of thermal expansion. 13) Highly stabilized innovative colloidal system according to claim 1, characterized by what has been described and proved. 